Metal Printing Template Carrier for Borderless Inkjet Transfer
Find Innovative SolutionsGenerate Solutions
Solution Overview
Problem
Aqueous inkjet printers struggle to achieve edge-to-edge printing on metal substrates, resulting in undesired margins and requiring additional plastic coverings to seal ink, which is cumbersome and prone to bubbles.
Innovation Solution
A printing template system using a carrier with a larger size than the metal panel, where the metal panel is attached with adhesive strips and a printable film is applied on top, allowing the printer to extend beyond the panel edges for borderless printing without additional coverings.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If aqueous inkjet printers print on metal substrates, then ink transfer is achieved, but edge-to-edge printing capability is lost resulting in undesired margins
Solution Approach 1:
A printable film is introduced as an intermediary carrier between the inkjet printer and the metal substrate. The film receives the inkjet print and then transfers it to the metal panel through heat activation, enabling edge-to-edge printing that would otherwise be impossible with direct metal printing
Solution Approach 2:
The printing process is segmented into distinct stages: (1) printing on the printable film, (2) heating to activate transfer, and (3) pressing onto the metal panel. This segmentation allows each stage to be optimized independently, particularly enabling the printer to work on a flexible film rather than rigid metal
2Reliability
If plastic coating is applied to seal ink on metal, then ink containment is improved, but product complexity and manufacturing difficulty increase
Solution Approach 1:
The separate plastic sealing coating is eliminated by integrating the sealing function into the printable film itself. The film is designed to be heat-activatable and adhesive, combining the sealing and bonding functions in a single material layer that is applied during the printing process
Solution Approach 2:
The printable film combines multiple functions: it serves as the printing substrate, the ink containment barrier, and the adhesive bonding layer. By merging these functions into one component, the system eliminates the need for separate plastic sealing coatings and simplifies the overall structure
3Manufacturing precision
If printable film extends beyond die cut area, then borderless printing is achieved, but excess material removal is required
Solution Approach 1:
The printable film is intentionally made larger than the final panel area to enable edge-to-edge printing coverage. The excessive film material is then removed through trimming or die-cutting after the transfer process, allowing the printing stage to achieve maximum coverage without concern for final dimensions
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
Enables borderless metal prints by allowing inkjet printers to print over the edges of the metal panel onto the carrier, eliminating the need for additional coatings and ensuring the metal panel is securely attached and easily removable.
Implementation Method 1
This 'sandwich' is then fed through heated rollers of a lamination device to activate the thermal adhesive coated on the metal panel, thereby bonding the printed film to the surface of the metal panel
Data Source
AI summary
This disclosure provides a printing template for use during an aqueous inkjet printing process in which ink is transferred onto a metal panel. The printing template includes a printable film having die cut area inside perimeter edge of its first layer, a generally flat metal panel having the same size as to that of the die cut area in the printable film, and a carrier having a recess which is sized and configured to encompass the shaped perimeter of the metal panel. The metal panel is secure within the die cut area and the recess in such a way that it is sandwiched between the printable film and the carrier during the printing process.